Three problems related to gas recirculation valve (egr valve) have been reported for the 2002 Ford Explorer. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Ford Explorer based on all problems reported for the 2002 Explorer.
My 2002 Ford Explorer had a failed tube mounted "differential pressue feedback from egr" (dpfe) sensor after 30k miles. Ford created a technical service bulletin (TSB) regarding this know issue affecting several 2000-2003 Ford models including the 2002 Explorer (see Ford TSB 04-11-1 may 25, 2004 ). However, when Ford turned this issue of the faulty dpfe sensor into a recall, or "field service action" (fsa) as they call it, they did not include the 2002 Ford Explorer in the dpfe recall. All vehicles included in fsa 02m01 were given an extended 2yr/24k mile warranty on the dpfe sensor. The 2002 Explorer was not included in this extended warranty despite the fact that the 2002 Explorer was included in the original TSB on this issue and the fact that the 2002 Explorer was know to use the same tube mounted differential pressure sensor as all the vehicles included in the recall. See fsa 02m01.
There is Ford TSB 02m01 and ntsb 10007207 for replacement of the egr sensor on 2002 Ford Explorers. The Explorer needed that sensor replaced, but the warranty claim was denied although my vehicle fell within age and mileage guidlines. I would like Ford to compensate me for the cost of the repair.
At a complete stop vehicle surges (accelerates). Have to place in neutral at standing stops to prevent an accident. Driver's side power window switch failed, had replaced, also the window whines when rolling up. Passenger's side power window regulator(cable) snapped?? when rear windows are down at a speed of 20 mph+ it sounds like a helicopter is in the back seat(actually physically hurts your ears!!!) <<<<no fix or repair?? anyone else have this problem? 55-65 mph steering wheel shakes. Repair attempt balanced and rotated tires and suspension was inspected. Still shakes. Rear spare tire accessories cover handle broke. <<not abused. How do you change a flat with no jack or no tools?? (spare tire came down alright though). Egr valve failure @ 40,000 miles. 4x4 intemittent shifting issues from low>auto and auto>high. Can not pin point problem. That about wraps up my lovely experience with this vehicle. I am a married father of two and the only one working on a limited income. I bought this truck with very low miles thinking it would be dependable not unaffordable.